Process for the production of the CHA-AFT zeolite intergrowth COE-10 and use thereof in heterogeneous catalysis

Abstract

A process for the production of a zeolitic material comprising one or more zeolite intergrowth phases of one or more zeolites having a CHA-type framework structure comprising SiO 2 and X 2 O 3 , and one or more zeolites having an AFT-type framework tructure comprising SiO 2 and X 2 O 3 , wherein X is a trivalent element, and wherein said process comprises: (1) preparing a mixture comprising one or more sources for SiO 2 , one or more sources for X 2 O 3 , and seed crystals comprising a zeolitic material, said zeolitic material comprising SiO 2 and X 2 O 3 in its framework structure and having a CHA-type framework structure; (2) heating the mixture prepared in (1) for obtaining a zeolitic material comprising one or more zeolite intergrowth phases; and (R) subjecting the zeolitic material obtained in (2) to a procedure for removing at least a portion of X from the framework structure of the zeolitic material.

The invention claimed is: 
     
       1. A process for the production of a zeolitic material comprising one or more zeolite intergrowth phases of one or more zeolites having a CHA framework structure comprising SiO 2  and X 2 O 3 , and one or more zeolites having an AFT framework structure comprising SiO 2  and X 2 O 3 , wherein X is a trivalent element, and
 wherein the process comprises: 
 (1) preparing a mixture comprising one or more sources for SiO 2 , one or more sources for X 2 O 3 , and seed crystals comprising a zeolitic material, wherein the zeolitic material comprises SiO 2  and X 2 O 3  in its framework structure and has a CHA framework structure; 
 (2) heating the mixture prepared in (1) for obtaining a zeolitic material comprising one or more zeolite intergrowth phases of one or more zeolites having a CHA framework structure and one or more zeolites having an AFT framework structure; and 
 (3) subjecting the zeolitic material obtained in (2) to a procedure for removing at least a portion of X from the framework structure of the zeolitic material; and 
 wherein the mixture prepared in (1) and heated in (2) comprises substantially no organotemplate. 
 
     
     
       2. The process of  claim 1 , wherein the zeolitic material obtained in (2) comprising one or more zeolite intergrowth phases of one or more zeolites having a CHA framework structure and one or more zeolites having an AFT framework structure, comprises COE-10. 
     
     
       3. The process of  claim 1 , wherein the zeolitic material comprised in the seed crystals in (1) is obtained by a process comprising:
 (A) preparing a mixture comprising one or more structure directing agents and a first zeolitic material comprising SiO 2  and X 2 O 3  in its framework structure, wherein the first zeolitic material has an FAU, FER, TON, MTT, BEA, MFI or combination thereof framework structure; and 
 (B) heating the mixture obtained in (A) for obtaining a second zeolitic material comprising SiO 2  and X 2 O 3  in its framework structure, wherein the second zeolitic material has a CHA framework structure. 
 
     
     
       4. The process of  claim 3 , wherein the first zeolitic material having an FAU framework structure comprises one or more zeolites having an FAU framework structure, wherein the one or more zeolites having an FAU framework structure are chosen from Li-LSX, zeolite X, zeolite Y, ECR-30, ZSM-20, LZ-210, SAPO-37, US-Y, CSZ-1, ZSM-3, Faujasite, and mixtures of two or more thereof. 
     
     
       5. The process of  claim 3 , wherein the mixture prepared in (A) and heated in (B) comprises substantially no phosphorous and/or phosphorous containing compounds. 
     
     
       6. The process of  claim 3 , wherein the framework of the zeolitic material obtained in (B) comprises substantially no phosphorous. 
     
     
       7. The process of  claim 3 , wherein the mixture prepared according to (A) further comprises one or more solvents. 
     
     
       8. The process of  claim 3 , wherein the mixture prepared in (A) and heated in (B) further comprises at least one source for OH — . 
     
     
       9. The process of  claim 3 , wherein the second zeolitic material having a CHA framework structure comprises one or more zeolites having a CHA framework structure, wherein the one or more zeolites having a CHA framework structure are chosen from Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21, |Li—Na| [Al—Si—O]—CHA, (Ni(deta)2)-UT-6, SSZ-13, SSZ-62, and mixtures of two or more thereof. 
     
     
       10. The process of  claim 3 , wherein the one or more structure directing agents comprises one or more tetraalkylammonium cation-containing compounds. 
     
     
       11. The process of  claim 10 , wherein the one or more tetraalkylammonium cation-containing compounds comprise one or more compounds of 1-adamantyltri(C 1 -C 3 )alkylammonium compounds, N,N,N-trimethyl-N-benzylammonium compounds, and mixtures of two or more thereof. 
     
     
       12. The process of  claim 10 , wherein the one or more tetraalkylammonium cation-containing compounds comprise one or more compounds of N,N,N-tri(C 1 -C 2 )alkyl-(C 5 -C 6 )cycloalkylammonium compounds, and mixtures of two or more thereof. 
     
     
       13. The process of  claim 1 , wherein the mixture prepared in (1) and heated in (2) comprises substantially no phosphorous, phosphorous containing compounds, or both. 
     
     
       14. The process of  claim 1 , wherein the framework of the zeolitic material obtained in (2) comprises substantially no phosphorous.